Double-Sided Jigsaw Puzzle and Method of Making The Same

ABSTRACT

A double-sided transparent plastic tessellated jigsaw puzzle and a method of making the same are disclosed. The puzzle is formed of a pair of clear acrylic 4′×8′ sheets having a thickness of about 0.060 inches. Images are printed on one side of each sheet and the sheets are laminated together with a pressure-sensitive film with the images in confronting relation. After rolling out air bubbles, the laminated sheet is laser cut to form a plurality of puzzles having a plurality of tessellations. The tessellations are formed as symmetrical or asymmetrical, identically shaped pieces that can be located in the puzzle in several different ways such that the images are the only guide to solution of the puzzle.

A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by any one of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to jigsaw puzzles and methods of making them and more particularly to double-sided jigsaw puzzles for use in entertainment and educational purposes.

2. Description of the Prior Art

Puzzles made of paper and other durable materials have entertained and educated since ancient times. The term “Jigsaw puzzle” is derived from the name of a cutting machine, namely, a jigsaw, which is typically used to make intricate straight and curved cuts in non-metallic sheet materials. Modern jigsaw puzzles are cut by many different types of machines other than the conventional jigsaw, for example, by using a steel rule die to cut flat sheets of material, much in the same way cookies are cut out from a flat sheet of dough by a cookie cutter. It is generally agreed that the first jigsaw puzzle was produced around 1760 by John Spilsbury, a London engraver and mapmaker. Spilsbury mounted one of his maps on a sheet of hardwood and cut the borders of the countries using a fine-blade marquetry saw. These puzzles endured as the primary tools for teaching geography to British children until about 1820. In the United States, jigsaw puzzles increased in popularity during the depression years (1929-1940). Today, despite the wide spectrum of entertainment activities to choose from, jigsaw puzzles still have a strong and loyal following. Usually, a modern day puzzler seeks entertainment and is unaware that the act of solving a puzzle stimulates complex mental exercises that help strengthen spatial reasoning and memory.

A tessellation or tiling is created when a one or more shapes is repeated over and over again and covers a plane surface without any gaps or overlaps. Tessellations frequently appear in the art of M. C. Esther and are used for many different embodiments and applications, e.g., to provide coverings and decorations for planar surfaces, such as pedestrian walks, walls, counter tops, etc. and to provide patterns for games, puzzles, coloring books and the like.

U.S. Pat. Nos. 5,230,508 and 4,824,112 to Tablet and Roy, respectively, both disclose the cutting of puzzle pieces using a laser apparatus.

U.S. Pat. No. 5,217,226 to Christopher discloses a complex three-dimensional puzzle made of a transparent plastic with one or more images imbedded and suspended in the plastic.

U.S. Pat. No. 6,309,716 and U.S. Pat. No. 5,945,181 both to Fisher disclose sets of tessellatable elements made of an acrylic plastic, in which a relatively low number of different elements may be combined together to provide attractive tessellating patterns.

U.S. Design patent Nos. D 320,050 to Mannino and D353,415 to Mitchell disclose double-sided jigsaw puzzles with tessellation patterns.

U.S. Pat. No. 5,520,388 to Osborn discloses a single shape figurative tessellation or tiling that may be used in puzzles, games and other recreations.

The foregoing prior art and other prior art jigsaw puzzles and tessellatable elements have not provided the unique combination of elements and the advantages of the double-sided jigsaw puzzle of the present invention. Nor does the prior art disclose the simple and effective method of making a double-sided jigsaw puzzle according to the present invention.

SUMMARY OF THE INVENTION

The present invention provides a two dimensional, interlocking and double-sided puzzle that is made out of acrylic with a seemingly suspended image and tessellated puzzle piece pattern. The present invention also provides a method of making a double-sided jigsaw puzzle.

According to its apparatus aspects, a first embodiment of the invention comprises a jigsaw puzzle with a double-sided image, with each side of the jigsaw puzzle having a different image. Each image of the jigsaw puzzle is seemingly floating or suspended within the puzzle by being sandwiched between two planar sheets of transparent acrylic, one on each outer side of the puzzle. The puzzle pieces of the invention, are formed preferably of a number identically shaped puzzle elements which, when tiled together to complete the puzzle images, create impressively noticeable tessellated patterns.

According to other embodiments of the invention, the images are printed as 3D or lenticular images, the puzzle pieces are formed of a number differently shaped puzzle elements or the sheets of acrylic plastic are lenticular. The combination of a 3D lenticular image or a 3D image and a lenticular acrylic sheet giving a moving 3D effect in addition to enhancing the floating or suspended appearance of the puzzle images on either side of the completed puzzle.

The puzzle of the invention is a jigsaw puzzle made of two planar or lenticular sheets of clear plastic, preferably an acrylic plastic material, or other clear plastic, such as a polycarbonate plastic sold under the tradename Lexan®. The same or different puzzle images are printed on one side of each clear plastic sheet, then bonded together using a pressure-sensitive film with the images back-to-back and cut into a jigsaw puzzle with puzzle pieces of one or more predetermined shapes by a laser cutting machine.

According to the method aspects of the present invention, a plurality of puzzle images are printed, by UV or screen printing or other printing process, such as sublimation, on one side of large sheets of clear acrylic plastic. After the images are printed on the acrylic sheets, a pressure-sensitive adhesive film is used to bond the two printed acrylic sheets together with the image sides in aligned and confronting relation. The individual puzzles are then cut out and the puzzle tessellations are cut in each puzzle by means of a laser cutting machine.

The proper acrylic material must be especially selected for thickness and its reaction to laser cutting. Although a ⅛-inch or thicker acrylic sheet may be selected, much time and energy is saved by choosing a 1/16-inch thick sheet of acrylic. The time and energy saved is crucial to the efficiency and expense of the mass production process and the floating image effect is still achieved with the thinner sheets of acrylic. After the puzzles are tessellated and laser cut from the two large bonded together acrylic sheets, the outermost peelable protective paper layers are removed and the individual puzzles are packaged.

With the foregoing and other objects, advantages and features of the invention that may become hereinafter apparent, the nature of the invention may be more clearly understood by reference to the following detailed description of the invention, the appended claims and to the several drawings forming a part hereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of one side of the assembled double-sided puzzle showing the tessellated puzzle pieces and an image illustration;

FIG. 2 is a plan view of the other side of the assembled double-sided puzzle showing the tessellated puzzle pieces and an image of text;

FIG. 3 is a perspective view of a single puzzle piece showing the layers of the puzzle piece;

FIG. 4 is a fragmentary view of a second embodiment of the puzzle of the invention;

FIG. 5 is a fragmentary view of a third embodiment of the puzzle of the invention; and

FIG. 6 is a fragmentary view of a fourth embodiment of the puzzle of the invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a front view of one embodiment of the assembled, double-sided puzzle 1 of the invention and FIG. 2 shows a rear view of the assembled puzzle 1. The puzzle 1 is formed of two bonded-together acrylic front and rear sheets IA and 1B, respectively. The respective borders 2, 3 of the front and rear sheets 1A, 1B of the puzzle 1 are preferably formed as one continuous piece, but may also be formed as a plurality of puzzle pieces (not shown) and, therefore, form part of the puzzle to be assembled. Images 4, 5, which may be the same or different, are printed on the back sides of the sheets 1A, 1B in confronting relation and may extend into the borders 2, 3 or not as desired. The bonded together sheets 1A, 1B are laser cut to form a plurality of identical interlocking tessellations 6 with no spaces between the tessellations 6.

As will be apparent to those skilled in the art from the puzzle illustrated in FIGS. 1 and 2, each symmetrical tessellation 6 may be inserted into the puzzle 1 at any location, in any one of three angular positions rotated 120° about its axis of symmetry and with its front or rear side facing upwardly. The identical and symmetrical tessellations and their particular shape make solution of the puzzle dependent entirely oh the image and, thus, much more challenging than a typical jigsaw puzzle having many differently shaped pieces and only a one-sided image. To make the puzzle 1 even more challenging, the symmetrical puzzle pieces 6 may each be trifurcated along any three vertical planes 120° apart into three smaller identical, but asymmetrical pieces (shown by the dashed lines 12 in FIG. 3) so long as the planes do not cut the piece 6 into more than three pieces. This will triple the number of identical puzzle pieces from the number of pieces 6 shown in FIGS. 1 and 2.

FIG. 3 illustrates an enlarged, perspective view of one of the single puzzle pieces or tessellations 6 of the puzzle 1 of the invention. The puzzle piece edges 7, 8 are laser cut from the bonded-together acrylic sheets 1A, 1B. The sheets 1A, 1B are printed prior to laser cutting, by UV or screen printing or other suitable printing process, on their inwardly confronting sides with one or more layers of ink 9, 10, then bonded together, preferably, with a pressure sensitive film 11. The film 11 may be transparent if the images are opaque or opaque if the images are either opaque or transparent. The dashed lines 12 illustrate how a single symmetrical puzzle piece 6 may be trifurcated into three asymmetrical, puzzle pieces as described above.

FIGS. 4-6 illustrate fragmentary views of other embodiments of the puzzle of the invention. In FIG. 4, for example, a puzzle 20 is formed with puzzle pieces or tessellations 21 of a simpler, identical and symmetrical shape than that of FIGS. 1 and 2, but having the same three angular possibilities for insertion into the puzzle 20 and the same possibilities for trifurcation into identical, but asymmetrical pieces. The border of the puzzle 20 may also be laser cut along planes 24, 25 or irregular lines (not shown) to form additional pieces 22, 23 of the puzzle 20.

In the FIG. 5 embodiment, a puzzle 30 is formed with puzzle pieces or tessellations 31 of an identical and symmetrical, but more complex shape than those of FIGS. 1-4. Each tessellation 31 may be inserted into the puzzle in any location, in any one of six angular positions rotated 60° apart and with its front or rear side facing upwardly. There is also the possibility of furcating each tessellation 31 into six identical, but asymmetrical tessellations (not shown) along any six vertical planes 60° apart so long as the planes do not cut the tessellation 31 into more than six pieces. The border of the puzzle 30 may also be laser cut along planes 34, 35 or irregular lines (not shown) to form additional pieces 32, 33 of the puzzle 30.

In the FIG. 6 embodiment, a puzzle 40 is formed with puzzle pieces or tessellations 41 of an identical and symmetrical shape. Each tessellation 41 may be inserted into the puzzle in any location, in any one of four angular positions rotated 90° apart and with its front or rear side facing upwardly. There is also the possibility of quadfurcating each tessellation 41 into four identical, but asymmetrical tessellations (not shown) along any four vertical planes 90° apart so long as the planes do not cut the tessellation 41 into more than four pieces. The border of the puzzle 40 may also be laser cut along planes 44, 45 or irregular lines (not shown) to form additional pieces 42, 43 of the puzzle 40.

According to the method aspects of the present invention, a plurality of puzzles are formed starting, for example, with two 4 feet×8 feet (4×8) sheets of clear acrylic plastic of any suitable thickness, but preferably 0.060 inch thick 4×8 sheets of colorless Acrylite® AR (abrasion resistant) acrylic sheet manufactured by Evonik Industries and provided with a scratch-and-tear resistant peelable protective paper layer applied to both sides of the sheets. After the peelable paper layer on one side of both 4×8 sheets is removed, each sheet is placed in the bed of a large format UV inkjet printer and printed on the paperless side in one or more ink layers with a plurality of identical images, e.g., six 30-inch by 20-inch images. The ink may be opaque or transparent and may also be applied by screen printing, although UV printing is preferred. Also, preferably, the images printed on the first sheet are different from the images printed on the second sheet, although the same images may be printed on both sheets.

After the images are printed on one side of each 4×8 acrylic sheet, a pressure-sensitive adhesive film, such as a FLEXcon® TT-202 2 mil thick pressure-sensitive film, is used to bond the two printed acrylic sheets together with the image sides in aligned and confronting relation. If the ink used is transparent, the pressure sensitive film should be opaque. The bonding may be accomplished by applying the pressure-sensitive adhesive film to one or both image sides of the sheets and rolling the aligned sheets through a roll laminator, such as a 60-inch GBC roller laminator, to securely bond the aligned sheets together and remove any air bubbles that may have formed between the sheets. Alternatively, the individual puzzle images (e.g., the 30-inch by 20-inch images) on one printed 4×8 sheet may be first cut out and then bonded with the individual images cut out from the other printed 4×8 sheet. In this way, the roller laminator may be of a smaller size.

According to other embodiments of the invention the images are printed as 3D or lenticular images, the puzzle pieces are formed of a number of differently-shaped puzzle elements or the sheets of acrylic plastic are lenticular. The combination of a 3D lenticular image or a 3D image and a lenticular acrylic sheet giving a moving 3D effect in addition to enhancing the floating or suspended appearance of the puzzle images on either side of the completed puzzle.

Now, the laminated 4×8 sheets (or the 30-inch by 20-inch sheets) still with the manufacturer's peelable protective paper layer on both outermost sides of the sheets are prepared for laser cutting. If the paper layer smokes excessively during lasing, either because of the type or quality of the paper or because of the type or power of the laser cutting machine, the peelable paper layer may be removed and replaced with an R Tape Conform Series® medium or low tack transfer tape manufactured by R Tape Corporation, 6 Ingersoll Road, South Plainfield, N.J. 07080. The laminated sheets are then placed in the cutting bed of a programmable laser cutting machine, which is preferably a 2000 watt CO2 laser with a bed large enough to accommodate a 4×8 acrylic plastic sheet. One suitable laser is a Mazak 2000 watt CO2. The lasing machine is programmed to cut the tessellations of each puzzle on the 4×8 sheet and to cut the periphery or outer edge of each of the plurality of puzzles on the 4×8 sheet.

After the laser cutting is completed, the cut sheets are removed from the laser cutting machine and placed between a pair of large planar surfaces. The uppermost planar surface is lifted from the sheet and the paper layer is treated with an aqueous solution that reacts with the paper adhesive and renders the paper more easily removable from the sheet with a sponge or squeegee. The uppermost planar surface is then placed back onto the now paper-free side of the laminated sheet, the sheet is turned over, the now-uppermost planar surface is raised from the laminated sheet and the paper layer is removed from that side of the laminated sheet as described above. The individual puzzles may now be bagged and/or packaged.

Although certain presently preferred embodiments of the invention have been specifically described herein, it will be apparent to those skilled in the art to which the invention pertains that variations and modifications of the various embodiments shown and described herein may be made without departing from the spirit and scope of the invention. Accordingly, it is intended that the invention be limited only to the extent required by the appended claims and the applicable rules of law. 

1. A jigsaw puzzle comprising a pair of planar transparent plastic sheets each having a thickness and first and second sides, first and second images applied on one of a respective first and second side of said sheets, said sheets being adhesively laminated together to form a single planar laminated sheet with the first and second images in confronting relation such that only one of said images is visible on opposite sides of said laminated sheet, a plurality of cuts made through said planar laminated sheet to form a plurality of tessellations having first and second tessellation sides and at least one peripheral shape and tessellation location in said puzzle, whereby each of said first and second images appears to be floating or suspended within the puzzle.
 2. The jigsaw puzzle of claim 1, wherein the peripheral shape of each tessellation is identical with no spaces between tessellations.
 3. The jigsaw puzzle of claim 2, wherein each tessellation is symmetrically shaped so as to be rotated about its axis of symmetry to fit into any tessellation location in said puzzle and in any one of a plurality of angular orientations in any tessellation location in said puzzle, the first tessellation side being coplanar with either side of the laminated sheet of the puzzle.
 4. The jigsaw puzzle of claim 3, wherein the plurality of angular orientations is three or more.
 5. The jigsaw puzzle of claim 2, wherein each tessellation is asymmetrically shaped to fit into any tessellation location in said puzzle, the first tessellation side being coplanar with either side of the laminated sheet of the puzzle.
 6. The jigsaw puzzle of claim 5, wherein each asymmetrically shaped tessellation can be oriented in any one of a plurality of angular orientations in said puzzle.
 7. The jigsaw puzzle of claim 6, wherein the plurality of angular orientations is three or more.
 8. The jigsaw puzzle of claim 1, wherein the first and second images are applied by printing using one or more layers of transparent ink and the plastic sheets are laminated together with an opaque pressure sensitive adhesive film.
 9. The jigsaw puzzle of claim 1, wherein the first and second images are applied by printing using one or more layers of an opaque ink and the plastic sheets are laminated together with a pressure sensitive adhesive film.
 10. The jigsaw puzzle of claim 1, wherein the puzzle has a continuous border.
 11. The jigsaw puzzle of claim 1, wherein the first and second images are different.
 12. The jigsaw puzzle of claim 1, wherein the thickness of each plastic sheet is about 0.060 inches.
 13. A method of making a double-sided jigsaw puzzle, comprising the steps of: providing a pair of planar transparent plastic sheets each having two sides, a thickness and a protective layer on both sides of said sheets; removing the protective layer from one side of each sheet; printing an image on said one side of each sheet; adhesively bonding the sheets together with said images in confronting relation to form a laminated sheet; laser cutting said laminated sheet to form a plurality of tessellations of said puzzle, each tessellation having first and second sides; and removing the protective layer from the other side of each sheet, whereby said images appear to be floating or suspended within the puzzle.
 14. The method of claim 13, wherein said laser cutting step includes forming said tessellations such that each tessellation is identical and symmetrically shaped so as to be rotated about its axis of symmetry to fit into any of a plurality of tessellation locations in said puzzle and in any one of a plurality of angular orientations in any tessellation location in said puzzle, the first tessellation side being coplanar with either side of the laminated sheet of the puzzle.
 15. The method of claim 13, wherein said laser cutting step includes forming said tessellations such that each tessellation is identical and asymmetrically shaped to fit into any tessellation location in said puzzle, the first tessellation side being coplanar with either side of the laminated sheet of the puzzle.
 16. The method of claim 13, wherein said printing step is one of UV printing or screen printing.
 17. A method of making a double-sided jigsaw puzzle, comprising the steps of: providing a pair of planar transparent acrylic plastic sheets each having two sides, a thickness of about 0.060 inches and a protective layer on both sides of said sheets; removing the protective layer from one side of each sheet; UV printing an image on said one side of each sheet; inserting a pressure sensitive film between said sheets with said images in confronting relation; rolling said sheets through a roller to laminate said sheets together and roll out air bubbles from between said sheets; laser cutting the laminated sheet to form a plurality of tessellations of said puzzle, each tessellation having first and second sides; and removing the protective layer from the other side of each sheet, whereby said images appear to be floating or suspended within the puzzle.
 18. The method of claim 17, wherein said laser cutting step includes forming said tessellations such that each tessellation is identical and symmetrically shaped so as to be rotated about its axis of symmetry to fit into any of a plurality of tessellation locations in said puzzle and in any one of a plurality of angular orientations in any tessellation location in said puzzle, the first tessellation side being coplanar with either side of the laminated sheet of the puzzle.
 19. The method of claim 17, wherein said laser cutting step includes forming said tessellations such that each tessellation is identical and asymmetrically shaped to fit into any tessellation location in said puzzle, the first tessellation side being coplanar with either side of the laminated sheet of the puzzle. 